engine SSANGYONG KORANDO 2012 Service Manual

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Key approval process in Smart key system equipped vehicle
The key approval consists of two processes; immobilizer key approval and Smart key
approval. ▶
Immobilizer key approval: When inserting the Smart key into Smart key slot, the power is supplied to the
key slot. SKM communicate with the Smart key in key slot to check if it has valid crypto code. If it is valid,
ECU start to control the engine when pressing the Engine Start/Stop button. The system has 10
seconds of valid time-out period. If the engine does not start in this period, the key approval process
should be done again.
Smart key approval: When pressing the Engine Start/Stop button or depressing the brake pedal without
Smart key inserted into the key slot, SKM communicate with the Smart key to check if it has valid crypto
code. If it is valid, the engine can be started.

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Front temp. sensor
(11) CDPF control
a. Overview
As the solution for environmental regulations and PM Particle Material) of diesel engine, the low emission
vehicle is getting popular. This vehicle is equipped with an extra filter to collect the soot and burn it again
so that the amount of PM in the exhaust gas passed through the DOC (Diesel Oxidation Catalyst) is
reduced. The CDPF (Catalyst & Diesel Particulate Filter) is an integrated filter including DOC (Diesel
Oxidation Catalyst) and DPF (Diesel Particulate Filter).
For details, refer to Chapter "CDPF".
b. Components
Rear temp. sensorCDPF (DOC+DPF)
Throttle valveD20DTF ECUDifferential pres.
sensorOxygen sensor

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Rear temp. sensor:
Measure DPF
temp.DPF performs
recycling
(combustion)
process at 600C,
and rear
temperature sensor
monitors the
temperature of DPF.
Differential pressure
sensor measures the
pressure difference
between pre-CDPF
and post-CDPF (If
PM has been
accumulated, the
measured value is
over the specified
value).Diff. pres. sensor:
Measure
pressure between
front side and
rear side of CDPF
Injector: Control
post injection
Front temp.
sensor: Measure
DOC temp.DOC performs
oxidation and
reduction process at
300~500˚C, and
front temperature
sensor monitors the
temperature of
DOC.
Electronic
throttle body:
Control intake ai
r
mass
ECU (DCM 3.7)
d. Operation process
When the differential pressure sensor detects the pressure difference between the front and the rear
side of CDPF, the sensor sends signal indicating the soot is accumulated and the post injection is
performed to raise the temperature of exhaust gas. The amount of fuel injected is determined according
to the temperature of exhaust gas detected by the rear temperature sensor. If the temperature is below
600°C, the amount of fuel injected is increased to raise the tem
perature. If the temperature is over
600°C, the amount of fuel injected is decreased or not controlled. When the engine is running in
low load range, the amount of post injection and the amount of intake air are controlled. It is to raise the
temperature by increasing the amount of fuel while decreasing the amount of intake air.
T-MAP sensor
Intake air
mass
Exceed PM
limitBooster
pressure/
temperaturePost injection
Control intake air
mass

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e. Cautions
Use only specified Engine Oil (approved by MB Sheet 229.51) for CDPF. -
1. Use only specified engine oil (Low Ash Oil)
The vehicle equipped with CDPF should use specific engine oil to improve the engine performance
and fuel economy, and ensure the service life of CDPF. -
2. Issue with normal engine oil
Sulfur, one of the contents of engine oil is burned and generates soot that is not regenerated by the
DPF. This remains on the filter as ashes and keeps accumulating. Eventually, this ashes will block the
filter. -
3. Benefit for specified engine oil
Minimized the sulfur content of engine oil which reduces the service life.
Improved fuel economy and emission level of CO2 with high performance and low viscosity.
Increased service life of engine oil with high resistance to temperature. -
-
-
4. Problems when using unspecified engine oil
The service life of filter may be reduced by 30% or more by the ashes accumulated on the filter.
The fuel economy may be reduced because of engine rolling resistance, frequent regeneration of
DPF. -
-
These problems are also caused by oil with high sulfur content, such as tax exemption oil and
heating oil, etc. *

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(2) CAN communication flow chart
Splice pack Wiring harness Location
S101 Floor wiring (LH) Under fuse & relay box in engine compartment
S102 Floor wiring (RH) Inside of right fender
S201 Main wiring Behind meter cluster (cowl cross member)
S202 Main wiring Behind meter cluster (cowl cross member)
S205 Floor wiring (LH) Under driver's door scarf

01-4
Engine mounting bracket
2. MAJOR COMPONENTS
Front View ▶
Cylinder head front cover
Timing gear case cover
EPS idler pulley
Alternator
Water pump pulley
A/C compressor
Crankshaft pulley
Oil pan assembly
Rear View ▶
Camshaft position sensor
Breather nipple
Purge control solenoid valveCoolant temperature sensor
Electronic throttle body
T-MAP sensor
MCC complete
VIS solenoid valve Cylinder head cover
Dual mass flywheel
Crankshaft position sensor
Hydraulic tensioner assembly

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3) General Instructions
Before lifting up the vehicle with a lift, correctly support the lifting points.
When using a jack, park the vehicle on a level ground and place the wheel chocks under the tires.
Position the jack under the frame and lift up the vehicle and then support with chassis stand before
service work.
Make sure to disconnect the negative (-) cable from the battery to prevent any damage to electric
systems.
If you have to work on vehicle, cover the seats and floor with protection covers to avoid any
damage and contamination.
Brake fluid and anti-freeze can damage the painted surface of body. So carefully handle them
during service work.
To improve the efficiency of service work, use only recommended and specified tools.
Use only Ssangyong genuine spare parts.
Never reuse the cotter pin, gasket, O-ring, oil seal, lock washer and self-locking nut. Replace them
with new ones. If reused, normal functions cannot be maintained.
Store the disassembled parts as a set based on disassembly order and unit.
Pay particular attention not to miss or mix the fasteners.
If necessary, especially for inspection, clean the removed parts completely.
Apply the oil or grease on the running and sliding surfeces before installation. Use the specified
sealant and gasket to prevent leakage if necessary.
Tighten the fasteners to the specified tightening torque.
As a final stage of service work, check if the serviced system is working properly and the problem
has been eliminated clearly. (1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14) Remove the engine and transaxle as a set.
Manual transaxle: Transaxle can be separated after removing the front module (sub frame, engine
and transaxle).
Automatic transaxle: Transaxle can be separated after removing the sub frame. -
-
2) Equipment
Korando is FF (Front Engine Front Drive) type vehicle, and engine and powertrain system are
integrated into a module. Therefore, 2-post lift and general equipment are necessary when working
on the engine and transmission.
Major equipment: Engine and transmission jack, Engine stand, Engine crane, Transmission jack,
Engine hanger -
-

01-8
4) Basic Inspection
(1) Horn operation
Listen for the horn sound when pressing the horn pad on the steering wheel. -
(2) Brake operation
Check if there is any abnormal noise, unusually long braking distance, or uneven braking force. If the
brake warning lamp does not go out even after starting the engien or are flashing during driving,
have the brake system checked immediately.
Check the brake pipes and hoses for connection, oil leak, crack or interference after changing the
position of tires. When replacing the tires, check the brake disc for surface condition and wear.
Check the parking brake cable and brake operation. Shorten the checking interval if the parking
brake is used frequently. -
-
-
(3) Exhaust system
Be aware to any changes in sound or smell from the exhaust system. These may be caused by leak or
overheat. Have the exhaust system checked and repaired immediately.
Inspect the exhaust system including catalytic converter. Inspect all the components and body frame
near the exhaust system. -
-
(4) Tires
Unusual vibration of the steering wheel and seats or pulling to one side on the straight and level roads
may indicates the uneven tire inflation pressure or poor wheel balance. -
(5) Steering and suspension system
Inspect the front and rear suspension and the steering system for damage, looseness or missing
parts, signs of wear or lack of lubrication. Inspect the power steering line and the hoses for
connection, leak, crack and chafing. Inspect the drive axle boot and seals for damage, tear or leak.
Replace or repair the system if necessary. -
(6) Engine oil
Check the oil level when the engine is still warm and add the specified engine oil if necessary. -
(7) Coolant
Check the coolant level in the coolant reservoir, coolant conditions (contamination, foreign material),
and hoses for damage and leak. Replace or add the Ssangyong genuine coolant, if needed. -
(8) Engine drive belt
Check all drive belts on the engine for wear, crack and looseness. Retighten or replace the belt, if
needed. -

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5) Guidelines on Engine Service
(1) Cautions before service works
Make sure to disconnect the negative (-) cable from the battery to prevent any damage to electric
systems.
Make sure to clean the working area and to prepare the necessary tools before service works.
Always place the ignition switch to OFF position if not required. Otherwise, there could be unexpected
damage to electric devices or personal injuries due to short-circuit.
To prevent the foreign material from entering into the fuel injection system, completely seal the inlets o
f
HP pump, fuel hoses and high pressure pipes.
To remoev the engine, use the dedicated equipments such as engine jack, transmission jack, engine
stand and engine crane. -
-
-
-
-
(2) Engine and accessories
When disassembling the engine, related parts (bolts, gaskets, etc.) should be stored as a set.
Clean the components completely with engine oil before assembling if needed.
Fully drain the engine oil, coolant and fuel from the vehicle and seal the inlets with the plugs before
removing the engine.
All the interference should be eliminated before removing the engine. -
-
-
- To prevent the personal injuries and vehicle damages that can be caused by mistakes during service
and to provide the optimized performance and safety after service works, the service technicials must
keep the basic cautions and service guidelines below. These could be easily forgotten during service
works.
Engine has a lot of precise components. The specified tightening torque and correct procedures should
be kept during service works. And, the working area is always clean and well prepared.
To prevent any damage to electric systems, make sure to disconnect the negative (-) cable from the
battery and place the ignition switch to OFF position before servicing.
Use only the specified parts with same ratings when replacing the electric devices. Check the
grounds and connections for looseness. -
-
(3) Electric devices
Extraordinary care should be taken when servicing the electric systems. Currently, the engine uses a lot
of electric devices. Short circuit and poor contact may cause the low engine performance, incomplete
combustion and other abnormalities.
When working with the fuel or oil systems in enclosed area, always keep the working area well-
ventilated and never allow anybody to smoke.
Gaskets and seals on the fuel and oil systems should be replaced with new ones. All bolts and nuts
should be tightened as specified.
Make sure to check the connections for leak after installation. -
-
-
(4) Fuel and lubrication system

01-12
4. CODING AND SETUP
1) Engine Variant Coding
Description Coding
Vehicle speed input to ECUCAN
with ABS or ESP: CAN
WIRE
Fan3 Relays
3 Relays
PWM fan
Auto cruiseNO
with Auto cruise system: YES
YES
Engine level controlNO
without Engine level control system: NO
(Korando)
YES
G-sensorNO
with 2WD ABS and non-ABS: NO
with 4WD ABS and ESP: YES
YES
Smart keyNO
with Smart key: YES
YES